Concrete cooling tower

ABSTRACT

A concrete cooling tower shell design made from a minimum number of precast factory-made parts. The shell is fabricated from three basic precast prestressed concrete building elements; namely: wall panels, T-beams, and louver posts. The wall panels and louver posts are positioned above a foundation to define the walls of the tower. The T-beams are positioned above the louver posts and wall panels to form the top deck of the tower. The Tbeams have spray nozzle openings formed therein and have a reinforced concrete topping poured thereon in a unique manner which utilizes extension members at each nozzle opening to form a corresponding opening therethrough. The topping includes curb portions to define a hot water distribution basin thereabove.

United States Patent 1 Furlong et al.

[ Dec. 18, 1973 1 1 CONCRETE COOLING TOWER [73] Assignee: Ec'odyneCorporation, Chicago, 111.

[22] Filed: Mar. 8, 1972 [2]] Appl. No.: 232,830

[52] US. Cl 261/111, 26l/DlG. 54, 52/292 [Sl] Int. Cl B0lf 3/04 [58]Field of Search 261/111 DIG. 11; 52/274, 292, 473

[56] References Cited UNITED STATES PATENTS 1,964,870 7/1934 Chappell52/274 2,104,874 1/1938 Levy 52/274 2,445,908 7/1948 De Flon et a1...261/111 2,577,323 12/1951 Goenner 52/274" 2,662,391 12/1953 Neil 52/2742,889,584 6/1959 De Flon 52/473 3,226,894 1/1966 Burchardt et a1....261/D1G. 11 3,226,935 1/1966 Schneller 52/274 3,300,942 l/l967 Horstman26l/D1G. 11

Primary Examiner-Frank W. Lutter Assistant Examiner Steven H. MarkowitzAtmrneyCharles M. Kaplan et al.

[ 5 7 ABSTRACT A concrete cooling tower shell design made from a minimumnumber. of precast factory-made parts. The shell is fabricated fromthree basic precast prestrcssed concrete building elements; namely: wallpanels, T- beams, and louver posts. The wall panels and louver posts arepositioned above a foundation to define the walls of the tower. TheT-beams are positioned above the louver posts and wall panels to formthe top deck of the tower. The T-beams have spray nozzle openings formedtherein and have a reinforced concrete topping poured thereon in aunique manner which utilizes extension members at each nozzle opening toform a corresponding opening therethrough. The topping includes curbportions to define a hot water distribution basin thereabove.

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PATENTED DEC 18 975 l CONCRETE COOLING TOWER BACKGROUND OF THE INVENTIONThis invention relates generally to the construction of cooling towers,and more particularly to the construction of an improved concretecooling tower shell design made from a minimum number of precastfactory-made parts which can be trucked to the jobsite.

The advantages of concrete construction of cooling towers instead ofwood are apparent, primarily due to the increased life of the structuresince the concrete structure will not deteriorate as does wood byrotting. Further, the need for expensive sprinkler systems iseliminatedand insurance premiums cost less. While cooling towers haveheretofore been made of prefabricated concrete parts, these towers havenot been able to economically compete with the conventional woodentowers. The heretofore known concrete tower designs have either utilizednumerous small light weight precast building elements, facilitatinghandling but requiring many time consuming steps to erect, or haveutilized large cast-in-place elements which have significantly increasedthe cost of the tower.

The present invention discloses a cooling tower constructed entirely ofconcrete, metal and plastic parts that is economically competitive withconventional wooden towers. This is accomplished by fabricating thetower from a minimum number of uniquely designed precast prestressedwall panels, T beams and louver posts. These structural elementsalthough relatively large in size, may be readily prefabricated and donot require a large amount-of field work during errection because of theunique interrelationship between the elements.

SUMMARY OF THE INVENTION It is a primary object of the present inventionto provide a cooling tower that is constructed entirely of concrete andplastic parts.

Another object is to provide a concrete cooling tower which utilizes aminimum number of factory-made concrete parts which can be trucked tothe jobsite.

A further object is to providea concrete cooling tower which utilizes aminimumnumber of interrelated precast concrete elements which arespecially designed to reduce field erection time.

Still another object is to providea concrete cooling tower whichutilizes a self-supporting structurev that does not require internalstructural support and therefore results in improved thermalperformance.

A still further object is to provide a unique simplified method ofconstructing such a concrete cooling tower in a manner which minimizesfield erection time.

Another object of the invention is to provide a concrete tower whichutilizes factory-made parts that can be put together in differentcombinations to form various multi-cell cooling towers.

To attain these and other objects the present invention provides aconcrete cooling tower, the shell of which is fabricated from threebasic precast prestressed building elements; namely: wall panels,T-beams and louver posts. The wall panels are precast to the necessarylength to permit them to be tilted up into position above a foundationin a simple one step operation. In a similar manner the louver posts areprecast and tilted up into position above the foundation. The louverposts containlouver blade receiving slots cast therein and anaerodynamic nose to reduce the pressure drop across the louver bladeassembly. The T-beams are positioned above the louver posts and wallpanels to form the top deck of the tower. The T-beams have spray nozzleopenings formed therein and have a reinforced concrete topping pouredthereon in a unique manner which utilizes extension members at eachnozzle opening to form a corresponding opening therethrough. The toppingfurther includes curb portions to define a hot water distribution basinthereabove. The tower filling is supported from the T-beams renderingunnecessary any internal structural support for the tower or fill thatwould retard the movement of air and interfere with thermal performance.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and many of theattendant advantages of this invention will be readily appreciated asthe same becomes better understood by reference to the followingdetailed description when considered in connection with the accompanyingdrawings, in which like reference numerals designate like partsthroughout the figures thereof and wherein:

FIG. 1 is a perspective view of a cooling tower constructed inaccordance with the present invention;

FIG. 2 is a top plan view of a portion of the foundation;

FIG. 3 is an enlarged plan view of a section of the foundationillustrated in FIG. 2;

FIG. 4' is an enlarged sectional view taken along line 4-4 in FIG. 3illustrating the connection of a louver post to the foundation;

FIG. 5 is an enlarged sectional view taken along line 5-5 in FIG. 3illustrating the connection of a wall panel to the foundation;

FIG. 6is a perspective view of an interior portion of the tower,partially broken away to show the interrelationship between thecomponent parts;

FIG. 7 is a perspective view illustrating a portion of the louver bladeassembly and its relationship to the foundation and top deck;

FlG. 8 is a top plan view of a portion of the top deck of the towerprior to pouring the topping thereon;

FIG. 9 is a sectional-view taken along line 9-9 in FIGS; 4

\ FIG. 10 is an enlarged plan view of the area encircled by line 10 inFIG. 8 showing the connection between the tops of adjacent wall panels;

FIG, 10A is an enlarged plan view of the area encircled by line 10A inFIG. 8 showing the connection between adjacent T-be ams;

FIG. 11 is an enlarged plan view of the area encircled by line 11 inFIG. 8 showing the connection between the ledger beam and the keystonebeam;

FIG. 12 is an enlarged plan view of the area encircled by line 12 inFIG. 8 showing the comer connection of a wall panel, a T-beam and alouver post;

FIG. 13 is a sectional view taken along line 13l3 in FIG. 8;

FIG. 14 is a sectional view taken along line l414 in FIG. 8;

FIG. 15 is an enlarged sectional view illustrating a spray nozzleopening in a T-beam with an extension attached thereto taken along line1515 in FIG. 18;

FIG. 16 is an enlarged plan view of the area encircled by line 16 inFIG. 8 showing the connection between the wedge shaped wall panel andthe wall panel adjacent thereto;

FIG. 17 is a sectional view taken along line 17-17 in FIG. 8',

FIG. 18 is a top plan view of a portion of the top deck of the towerwith the topping poured thereon;

FIG. 19 is a sectional view taken along line 19-19 in FIG. 18;

FIG. 20 is a sectional view taken along line 20-20 in FIG. 18;

FIG. 21 is a sectional view taken along line 21-21 in FIG. 18;

FIG. 22 is a sectional view taken along line 22-22 in FIG. 18;

FIG. 23 is a sectional view taken along line 23-23 in FIG. 18;

FIG. 24 is a sectional view taken along line 24-24 in FIG. 18;

FIG. 25 is a sectional view taken along line 25-25 in FIG. 18;

FIG. 26 is a sectional view taken along line 26-26 in FIG. 18;

FIG. 27 is a sectional view taken along line 2727 in FIG. 18;

FIG. 28 is a sectional view taken along line 28-28 in FIG. 18.

FIG. 29 is a sectional view of a portion of the deck illustrating theconnection of the fill assembly, and

FIG. 30 is an enlarged view of a detail in FIG. 29.

DESCRIPTION OF A PREFERRED EMBODIMENT Since the present inventionprimarily relates to a novel concrete tower shell design, and the methodof construction thereof, this disclosure will not concern itself withthe interior details such as the hanging fill assembly, drift eliminatorassembly, or the fan drive assembly. These assemblies are of the generaltype disclosed in copending U. S. application Ser. No. 63150 filed onAug. 12, 1970, and assigned to the same assignee as the presentinvention.

Referring to FIG. 1, the exterior shell of a three cell crossflowconcrete cooling tower l0, constructed in accordance with the presentinvention, includes a foundation 1 1, wall sections 12, louver bladeassembly 13, distribution pipes 14, top, deck and fan stacks 16. Thehereinbelow description discloses the specific construction of theexterior shell of tower 10 which is made up of the foundation 11, wallsections 12, louver blade assembly 13 and the top deck '15. In order tosimplify the disclosure the majority of the drawings and the disclosureare drawn to the shell structure of half of one cell. It should beunderstood that the other half of the cell is the mirror immage of thedisclosed half and that the other cells of the tower are substantiallyidentical thereto.

Referring to FIGS. 2-7 and specifically to FIGS. 2 and 3, there is showna reinforced concrete foundation 1 l which includes footings 22 andfloor 24. Footings 22 include longitudinally extending outer sections 25and 26, a centrally disposed longitudinal section 27 and a plurality oftransversely extending sections 28 which divide the foundation into aplurality of grids. 29; such that two transversely adjacent grids 29correspond to each cell of the tower. Each grid 29 has a floor 24 whichserves as the cold water basin for the corresponding cell. Floor 24 ispreferrably poured-in-place, with reinforcing mesh 37 positionedtherein, after the pouring of footings 22. Floor 24 includes aprojection 31 extending about the periphery thereof which is received bya corresponding notch33 recessed into the sides of footings 22, as seenin FIGS. 4 and 5. A poured curb section 35 extends upwardly from theouter edges of the sections 25 and 26 to define the outer limits offoundation 11.

Formed within footing sections 27 and 28 are recessed channels 30 whichextend substantially the entire distance between the outer peripheriesof foundation 11. Associated with each of the sections 25 and 26 is aset of spaced apart recessed rectangular cavities 32 which extendsubstantially the entire length of the tower. Formed within footings 22and extending respectively into channels 30 and cavities 32 areanchoring bolts 34, the positioning of which are indicated by marks inFIG. 3. Bolts 34 include threaded upper section 36 which extend intochannels 30 and cavities 32, respectively illustrated in FIGS. 5 and 4.

Positioned within channels 30 are a plurality of substantially identicalprecast prestressed concrete wall panels 40, the construction of whichis best illustrated in FIG. 6. Each panel 40 is a large one piecestructural member (e.g. 40 feet in length)'which extends the entiredistance between foundation 11 and top deck 15. Panel 40 is precast asan integral unit and includes a pair of spaced apart vertical ribsections 42 of increased thickness which extend outward from a flangesection 44 and which meet a horizontal rib section 46 of similarincreased thickness positioned adjacent the top end of flange section44. The lower ends of rib sections 42 extend beyond the lower end offlange portion 44 and include metal base connecting plates 47 secured tothe bottom surface thereof in a conventional manner, as by welding toconnecting rods (not shown) precast into ribs 42. Plates 47 extendbeyond both sides of ribs 42 and include holes therethrough spaced apartfor receiving rods 34 within channels 30. Prestressed reinforcing rods48 extend the entire length of panel 40.

Wall panels 40 are lifted up into position within channels 30 such thatends 36 of bolts 34 pass through the corresponding holes at both ends ofconnecting plates 4' 7. As seen inFlG. 5, a locking nut arrangement 47'fastens plate47 to bolts 34. Panels 40 are positioned and secured withinchannels 30 in a abutting relationship over the entire extent ofchannels 30 to form transverse wall sections 12 and partition sections12'. Embedded within the top surface of rib section 46 is a pair of weldplates 49 located at opposite ends thereof for securing adjacent panels40 together. Adjacent weld plates 49 of abutting wall panels 40 arewelded to a plate 50 spanning across the abutting edges of therespective panels 40, as best seen in FIG. 10. Embedded within the topsurface of rib section 46 in vertical alignment with rib sections 42 areweld plates 94, as seen in FIG. 17. The wall panels at the intersectionbetween the inclinedlouver blade assembly 13 and the wall sections 12are wedge shaped to fill in the area therebetween, as indicated at 41 inFIG. 6. Wall sections 12 and 12' serve both to support a substantialportion of the top deck 15 and the mechanical equipment associatedtherewith and to partition the tower into its respective cells.

\ Referring to FIG. 7, the louver blade assembly 13 includes a pluralityof louver posts 52 for supporting louver blades 54 therebetween. Eachlouver post 52 is a large one piece structural member which is inclinedupwardly and outwardly from foundation 11 to top deck 15. Each louverpost 52 is a precast concrete member, cast as an integral unit withprestressed reinforcing network 55 formed therein; which includes a noseportion 56 formed along the outer edge thereof to an aerodynamic shapewhich reduces resistance to air flow. Cast within post 52 are aplurality of vertically spaced slots 58 which are inclined upward andoutward for receiving louver blades 54. The lower end of nose portion 56terminates shortlof the bottom of posts 52. As best seen in FIG. 4, ametal base connecting plate 59, recessed within the bottom surface ofpost 52, and connected thereto in a conventional manner, extends beyondthe outer and inner surfaces thereof and includes holes therethrough forreceipt of corresponding bolts 34 positioned within cavitites 32. Theupper inside surface of post 52 is notched at 60 to form a supportingsurface 62. A weld plate 64 is embedded within the upper surface of post52. v

Louver posts 52 are lifted into position within corresponding cavities32 such that bolts 34 pass through the corresponding holes in plate 59to be secured in place by locking nut assemblies 65, as seen in FIG. 4.Louver blades 54 are positioned within slots 58 to complete constructionof louver blade assembly 13.

Channels 30 and cavities 32 are filled with a cementitious grout, asindicated at 66 in FIGS. 4 and 5, to further stabalize wall sections 12and louver blade assembly 13. The wall panels 40 and louver posts 52 arespecially designed to be economically precast out of prestressedreinforced concrete at local precast concrete yards located near the'jobsite and then trucked to the jobsite. Connecting plates 47 and weldplates 49 and'94 are preferably precast into panels 40 prior to shipmentto the jobsite. Likewise, connecting plate 59 and weld plate 64 arepreferably precast into louver post 52 at the precast yard.

Top deck 15, supported upon the upper edges of 'wall panels 40 andlouver posts 52, serves as the roof of the tower shell so as to definethe cooling chamber therebelow and a hot water distribution systemthereabove. Referring to FIGS. 6, 8, and 18, the top deck l5 isillustrated as including a pair of precast prestressed double T-beams 70and 70, precast prestressed concrete top panels 72, and apoured-in-place concrete topping 74. Since T-beams 70 and 70' aresubstantially identical in construction, the corresponding parts of beam70 are indicated by the same number as the part in beam 70 with theaddition of a prime sign. The hereinbelow disclosed method ofconstructing top deck forms an important part of the present invention.

Each double T-beam 70 is integrally cast to include a flange portion 75and'a pair of spaced longitudinally extending ribs 76 extendingdownwardly therefrom. The end portions of ribs 76 extend beyond theedges of flange portion 75 as indicated at 77 in FIG. 6. Flange portion75 includes a plurality of spray nozzle openings 78 formed therethrough,which are lined with opening defining inserts 103 adaptable to receiveupwardly extending nozzle hole defining plastic extensions 105, as seenin FIG. 15. Reference is made to U.S. Pat. application Ser. No. 273065,filed concurrently herewith and assigned to the same assignee as thepresent invention, for a disclosure of the method and apparatus used toprecast beams 70. Embedded along both longitudinal edges of flangeportion 75 are a plurality of spaced apart metal weld plates 79 formedtherein, indicated by X-marks in FIG. 8. Beam is precast withreinforcing wire mesh 80 formed within flange portion 75 and reinforcingrods 82 formed within ribs 76. Embedded within the bottom of ribs 76, atthe outside edges thereof, are weld plates 96.

Referring to FIG. 8, the portion of the top deck 15 corresponding toeach half cell includes two beams 70 plates 64 in post 52. Connectingplates 84 are welded at opposite ends to plates 79' and thecorresponding plates 64 secure the outer edge of beam 70' to louverposts 52. As seenin FIG. 17, weld plates 96 in ribs 76 are welded toweld plates 94 in rib section 46 to secure beam 70 to wall panel 40. Aspacer element may be required to level beam 70. Referring to FIG. 10A,the inner edges of beams 70' are secured to the outer edges of beams 70by welding the opposite ends of connect-' ing plates 86 respectively toadjacent plates 79 and 79' positioned respectively along side oneanother. Referring to FIG. 12, the posts 52 which are in transversealignment with awall panel 40 include a-plate 88 em.- bedded in surface62 thereof which in turn is connected to plate 49 of panel 40 by aconnecting plate 90 welded at its opposite ends thereto. The bottomsurface of section 77 has a plate 92 connected thereto which is likewisewelded to plate 88. This three-way corner connection is used to rigidlysecure together wall panels 40, T-beams 70' and posts 52 at the fourcorners of each cell. Referring to FIG. 16, the top surface of panel 41is secured to the top surface of the adjacent panel 40 by a connectingmember 98, secured at its opposite ends respectively thereto by nuts 99received by bolts embedded within the panels.

Referring to FIGS. 6, 8, and 14, a ledger beam 100 longitudinallyextends between adjacent wall sections 12 at the inner edge of T-beam70. The outer horizontal surface of beam 100 has weld plates 102 formedtherein which are connected to the weld plates 79 along the inner edgeof beam 70 by connecting plates 104, welded at opposite endsrespectively thereto. Supported on surface 106, notched from beam 100,are a pair of transversely extending spaced. keystone beams 108 whichextend to the ledger beam 100 associated with theother half of the cell.As seen in FIG. 11, ledger beam 100 .hasla weld plate 110 embeddedwithin the top surface thereof which is in transverse alignment with aweld'p late 112 embedded within the top surface of keystone beam 108.Connecting plate 114 is welded at its opposite ends respectively to weldplates 1 l0 and 112. 1

Referring to FIGS. 8. 9, 21, and 23, a set of precast top deck panels 72are positioned on top of ledger beam 100, keystone beams 108 and wallsections 12. The set of panels 72 includes three panels 115, 117,

- and 119, which when positioned in place define a semicircular fanstack opening 120. The edges of panels 115 and 119 are supportedimmediately above ledger beams 100, keystone beams 108, and a section ofa concrete bond beam 122 positioned atop of wall panels 40, as best seenin FIG. 21. Panel 117 is supported above ledger beam 100 and bothkeystone beams 108.

The curved edges of panels 115, 117, and 199 which define a fan opening120 are formed by a curved channel iron 124 east integral with the edgesthereof.

A poured-in-place reinforced concrete topping 74 covers T-beams 70 and70, and panels 72. Referring to FIGS. 18--22, topping 74 is formed so asto define curb portions 130, 132, and 134. Suitable concrete holdingforms may be employed in accordance with conventional practice. Curbportions 130, 132, and 134 define a hot water distribution basin 139therebetween. Prior to pouring the portion of concrete topping 74 whichcovers T-beams 70 and 70, the extensions 105 are secured to inserts 103defining holes 78, as seen in FIG. 15. Tops 107 are releasablypositioned on the upper edges of extensions 105 closing the openingstherethrough. The concrete is poured to a depth reaching the upper edgesof extensions 105 and allowed to set. Upon removal of tops 107, openings78 extend through topping 74 and thereby permit'water from distributionbasin 140 to flow therethrough. Also formed integral with topping 74 aredistribution pipe mounting blocks 139 having pipe retaining members 142extending upwardly therefrom.

In the process of erection of the shell of tower 10, the foundation 1 1is first poured-in-place at the jobsite with channels 30 and cavities 32formed therein and anchoring bolts 34 extending therethrough. Theprecast wall panels 40 are then tilted up into position within channels30 and plates 59 are secured to botls 34 of locking nut assemblies 47 soas to form wall sections 12 and 12. Precast double T-beams 70 are thenpositioned in place above wall sections 12 and weld plates 96 are weldedto weld plates 94. Precast ledger beams 100 are next positioned in placeabove wall sections 12 and secured to the inner edges of beam 70 bywelding plates 79 and 102 to connecting plates 104. Precast keystonebeams 108 are then positioned in place upon surfaces 106 of ledger beams100 and secured thereto by welding plates 114 to plates 110 and 112. Theprecast louver posts 52 are tilted up into position within cavities 32and plates 59 are secured to bolts 34 by locking nut assemblies 65 toform louver assembly 32. With the louver posts 52 in place, the double Tbeams 70 are then positioned above wall sections 12 and louver assembly13. Corresponding weld plates 79 and 79' are secured together byconnecting plates 86 and weld plates 79 are secured to the correspondingplates 64 in posts 52 by connecting plates 84. Weld plates 92' aresecured to weld plates 88 and weld plates 49 and 88 are secured togetherby connecting plates 90. A concrete bond beam 122 is then positioned ontop of wall section 12 and 12', after which the precast fan deck panels115, 117, and 119 are positioned in place. The pouring of topping 74,defining openings 78 therethrough and curb portions 130, 132 and 134 andblocks 140 thereon, completes construction of the shell.

The cooling tower shell construction of this invention is made byattaching together-wall panels 40, louver posts 52, T beams 70, ledgerbeams 100, keystone beams 108 and top deck panels 72; all of which havebeen factory-made of precast, prestressed concrete and trucked to thejobsite. These parts can be put together in different combinations toform multi-cell cooling towers. This design greatly reduces the fieldwork necessary to construct the tower and thus makes the insurabilityand fire resistance of concrete construction obtainable at an acceptablecost.

Referring to FIGS. 29 and 30, a fill hanger assembly of typecontemplated for use with the concrete tower shell of the presentinvention is illustrated as including support tubes 151 which extendtransversely below the T beams 70 and 70 and are secured thereto bybolts 152 which are received by fittings 154 in ribs 76 and 76'.Suspended from tubes 151 are wire fill hangers 155 which extend fromtubes 151 substantially the entire height of the fill area and define aplurality of parallelogram grids 156 for support of fill strips 158.Fill strips 158 are of the type disclosed in U. S. Pat. No. 3,468,521,assigned to the same assignee as the present invention. Reference ismade to U. S. Pat. application Ser. No. 63150, assigned to the sameassignee as the present invention, for disclosure of horizontalstabilizers and transverse stabilizers which may be used to increase therigidity of fill hanger assembly 150.

Construction of the tower shell in accordance with the present inventionand suspending the fill hanger assembly as mentioned above eliminatesthe need for internal structural supports and fill hanger supports whichcause resistance to air flow and thus increase the pressure drop acrossthe fill area. Such construction further permits a continuous spacingpattern of the fill strips throughout the fill area thus eliminatingundesirable air and water gaps which interfere with thermal performance.

Various modifications are contemplated and may obviously be resorted toby those skilled in the art without departing from the spirit and scopeof the invention, as hereinafter defined by the appended claims, as onlya preferred embodiment thereof has been disclosed.

What is claimed is:

1. A method of constructing a concrete cooling tower shell, comprisingthe steps of a. pouring a reinforced concrete foundation having aplurality of substantially parallel recessed channels formed therein,extending substantially the entire width thereof, and a pair ofsubstantially parallel sets of recessed cavities formed therein,extending substantially the entire length at the outer longitudinalperipheries thereof;

b. raising precast concrete wall panels to a position wherein the lowerends thereof are immediately above the recessed channels;

c. lowering the precast wall panels into the recessed channels andsecuring them to the foundation so as to form a self supporting wallsection;

d. raising precast concrete louver posts to a position wherein the lowerends thereof are immediately above the recessed cavities;

e. lowering the precast louver sections into the recessed cavities andsecuring them to the foundation so as to form a self supporting louversection; and

f. supporting a top deck constructed from a plurality of precastprestressed concrete beams, having spray nozzle openings formed therein,positioned f adjacent one another on the upper ends of the wall panelsso as to form a self-supporting and unobstructed cooling chamber definedby the wall panels, the foundation, the louver posts and the beams.

2. The method as defined in claim 1 further including the step ofpouring a reinforced concrete topping above the beams having openings invertical alignment with the spray nozzle openings in the beams.

3. The method as defined in claim 2 wherein the reinforced concretetopping includes curb portions so as t define a hot water distributionbasin.

4. The method as defined in claim 1 further including the steps offilling the recessed channels and recessed cavities with a non-shrinkingcementitious material.

5. The method as defined in claim 1 wherein the precast louver postsinclude louver blade slots formed integral therewith for receipt oflouver blades.

6. A cooling tower structure comprising: a reinforced concretefoundation having substantially parallel recessed channels formedtherein transversely extending substantially the entire width thereofand substantially parallel sets of recessed cavities formed thereinlongitudinally extending substantially the entire length and at theouter peripheries thereof; a plurality of precast prestressed concretewall panels having their lower ends positioned within said recessedchannels and secured to said foundation; a plurality of precastprestressed concrete louver posts having their lower ends positionedwithin said cavities and secured to said foundation; and a top deckincluding a plurality of precast prestressed concrete beams, havingspray nozzle openings formed therein, extending across the uppersurfaces of said wall panels, thereby forming a self-supporting andunobstructed cooling chamber defined by said wall panels, saidfoundation, said louver posts, and said beams.

7. The invention defined in claim 6, wherein said wall panels are formedso as to include spaced substantially vertically rib sections extendingsubstantially the entire length thereof.

8. The invention defined in claim 7 wherein said top deck includes aplurality of double T-beams, including a pair of downwardly extendingribs, the outer ends of which are supported immediately above said ribsections of said wall panels.

9. The invention defined in claim 6 wherein said louver posts includelouver blade slots formed therein for receipt of the louver blades.

10. The invention defined in claim 9 wherein said louver posts have anaerodynamic nose formed at the exterior edge thereof so as to reduce thepressure drop across the louver posts.

11. The invention defined in claim 8 wherein said louver posts include anotched seat formed at the upper interior edge thereof for receipt andsupport of a bottom surface of said double T beam ribs.

12. The invention defined in claim 6 wherein a reinforced concretetopping is provided above said beams having curb portions integraltherewith so as to define a hot water basin having spray nozzle openingstherethrough.

13. The invention defined in claim 6 wherein the inner edges of theinnermost beams are supported upon longitudinally extending concreteledger beams extending between adjacent parallel wall panels.

14. The invention defined in claim 13 further including concretekeystone beams extending between said ledger beams and a-plurality ofprecast concrete top deck panels supported upon said ledger beams andsaid keystone beams, shaped so as to define a fan stack openingtherethrough.

15. The invention defined in claim 14 wherein said concrete toppingcovers said top deck panels.

16. A multi-cell cooling tower structure comprising: a reinforcedconcrete foundation having a plurality of transversely extendingsubstantially parallel recessed channels formed therein extendingsubstantially the entire width thereof; and a pair of longitudinallyextending substantially parallel sets of recesses cavities formedtherein extending substantially the entire length and at the outerlongitudinal peripheries thereof; a plurality of precast prestressedwall panels having their lower ends positioned within said recessedchannels and secured to said foundation, defining individual coolingcell therebetween; a plurality of precast prestressed concrete louverposts having their lower ends positioned within said cavities andsecured to said foundation; and a plurality of precast prestressedconcete T beams extending across the upper ends of said wall panels,forming a top deck for each cell, having spray nozzle openings formedtherein, so as to form a plurality of self-supporting and unobstructedcooling cells defined by said wall panels, said foundation, said louverposts, and said T beams.

17. The invention as defined in claim 16 wherein said foundation furtherincludes a longitudinally extending recessed channel positionedsubstantially equadistant from each of said sets of recessed cavities,and a plurality of precast prestressed concrete wall panels having theirlower ends positioned therein so as to define partition walls separatingeach cell into two sections.

18. The invention defined in claim 20 wherein said louver posts includelouver blade slots formed therein having an aerodynamic nose formed atthe exterior edge thereof. thereof.

UNITED STATES PATENT OFFICE CERTIFICATE OF CORRECTION Patent No. 3 a 779a 523 Dated December 18 1973 Donn B. Furlong et a1, Inventor(s) It iscertified that error appears in the above-identified patent and thatsaid Letters Patent are hereby corrected as shown below:

New I75]- Robert G rother should read a? Robert G-roth'ee r '1' Signedand sealed this 13th day of May 1975.

(SEAL) Attest:

C. MARSHALL DANN RUTH C. MASON Commissioner of Patents Attesting Officerand Trademarks F ORM PO-105O (IO-69) USCOMM DC 6375 P59 u.s GOVERNMENTPRINTING OFFICE: 93 o zg ggg UNITED STATES PATENT OFFICE CERTIFICATE OFCORRECTION Patent No. 3.779.523 Dated December 18, 1973 Inventofls) DonnB. Furlong, Harry W; Gobler and Robert Grother- It is certified thaterror appears inthe above-identified patent and that said Letters Patentare hereby corrected as shown below:

In column 6, line 57, delete after "8" and insert In column" 6, line 64,the Word "beams" (first occurrence) should be --beam--.

In column 7, linel, "the number "199" should be --119--.

In column 7, line 29, the Word "botls" should be -bolts--.

In column 7, line 42, the number "32" should be -l3---.

In column 10, linelZl, the word "rec esses' should be "recessed".

' In column .10, line 27, .the word "cell" should be --cells- I 3 Incolumn -l O, line 45, the number "20" should -l7--.

In column 10, line 48, delete the second "thereof";

Signed and sealed this lhth day of May 197i}.

(SEA-L.) Attest:

ZLDE'JARD .FLLFI TZQI i Iii C I' MRSEL ILL DANE I .1 v I. i: fittestlni9f 7 lommissloner of Patents

1. A method of constructing a concrete cooling tower shell, comprisingthe steps of : a. pouring a reinforced concrete foundation having aplurality of substantially parallel recessed channels formed therein,extending substantially the entire width thereof, and a pair ofsubstantially parallel sets of recessed cavities formed therein,extending substantially the entire length at the outer longitudinalperipheries thereof; b. raising precast concrete wall panels to aposition wherein the lower ends thereof are immediately above therecessed channels; c. lowering the precast wall panels into the recessedchannels and securing them to the foundation so as to form a selfsupporting wall section; d. raising precast concrete louver posts to aposition wherein the lower ends thereof are immediately aboVe therecessed cavities; e. lowering the precast louver sections into therecessed cavities and securing them to the foundation so as to form aself supporting louver section; and f. supporting a top deck constructedfrom a plurality of precast prestressed concrete beams, having spraynozzle openings formed therein, positioned adjacent one another on theupper ends of the wall panels so as to form a self-supporting andunobstructed cooling chamber defined by the wall panels, the foundation,the louver posts and the beams.
 2. The method as defined in claim 1further including the step of pouring a reinforced concrete toppingabove the beams having openings in vertical alignment with the spraynozzle openings in the beams.
 3. The method as defined in claim 2wherein the reinforced concrete topping includes curb portions so as todefine a hot water distribution basin.
 4. The method as defined in claim1 further including the steps of filling the recessed channels andrecessed cavities with a non-shrinking cementitious material.
 5. Themethod as defined in claim 1 wherein the precast louver posts includelouver blade slots formed integral therewith for receipt of louverblades.
 6. A cooling tower structure comprising: a reinforced concretefoundation having substantially parallel recessed channels formedtherein transversely extending substantially the entire width thereofand substantially parallel sets of recessed cavities formed thereinlongitudinally extending substantially the entire length and at theouter peripheries thereof; a plurality of precast prestressed concretewall panels having their lower ends positioned within said recessedchannels and secured to said foundation; a plurality of precastprestressed concrete louver posts having their lower ends positionedwithin said cavities and secured to said foundation; and a top deckincluding a plurality of precast prestressed concrete beams, havingspray nozzle openings formed therein, extending across the uppersurfaces of said wall panels, thereby forming a self-supporting andunobstructed cooling chamber defined by said wall panels, saidfoundation, said louver posts, and said beams.
 7. The invention definedin claim 6, wherein said wall panels are formed so as to include spacedsubstantially vertically rib sections extending substantially the entirelength thereof.
 8. The invention defined in claim 7 wherein said topdeck includes a plurality of double T-beams, including a pair ofdownwardly extending ribs, the outer ends of which are supportedimmediately above said rib sections of said wall panels.
 9. Theinvention defined in claim 6 wherein said louver posts include louverblade slots formed therein for receipt of the louver blades.
 10. Theinvention defined in claim 9 wherein said louver posts have anaerodynamic nose formed at the exterior edge thereof so as to reduce thepressure drop across the louver posts.
 11. The invention defined inclaim 8 wherein said louver posts include a notched seat formed at theupper interior edge thereof for receipt and support of a bottom surfaceof said double T beam ribs.
 12. The invention defined in claim 6 whereina reinforced concrete topping is provided above said beams having curbportions integral therewith so as to define a hot water basin havingspray nozzle openings therethrough.
 13. The invention defined in claim 6wherein the inner edges of the innermost beams are supported uponlongitudinally extending concrete ledger beams extending betweenadjacent parallel wall panels.
 14. The invention defined in claim 13further including concrete keystone beams extending between said ledgerbeams and a plurality of precast concrete top deck panels supported uponsaid ledger beams and said keystone beams, shaped so as to define a fanstack opening therethrough.
 15. The invention defined in claim 14wherein said concrete topping covers said top deck panels.
 16. Amulti-cell cooling tower structure comprising: a rEinforced concretefoundation having a plurality of transversely extending substantiallyparallel recessed channels formed therein extending substantially theentire width thereof; and a pair of longitudinally extendingsubstantially parallel sets of recesses cavities formed thereinextending substantially the entire length and at the outer longitudinalperipheries thereof; a plurality of precast prestressed wall panelshaving their lower ends positioned within said recessed channels andsecured to said foundation, defining individual cooling celltherebetween; a plurality of precast prestressed concrete louver postshaving their lower ends positioned within said cavities and secured tosaid foundation; and a plurality of precast prestressed concete T beamsextending across the upper ends of said wall panels, forming a top deckfor each cell, having spray nozzle openings formed therein, so as toform a plurality of self-supporting and unobstructed cooling cellsdefined by said wall panels, said foundation, said louver posts, andsaid T beams.
 17. The invention as defined in claim 16 wherein saidfoundation further includes a longitudinally extending recessed channelpositioned substantially equadistant from each of said sets of recessedcavities, and a plurality of precast prestressed concrete wall panelshaving their lower ends positioned therein so as to define partitionwalls separating each cell into two sections.
 18. The invention definedin claim 20 wherein said louver posts include louver blade slots formedtherein having an aerodynamic nose formed at the exterior edge thereof.thereof.